PL DIFFERENTIAL AND DRIVELINE 3-1

DIFFERENTIAL AND DRIVELINE

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION INNER TRIPOD JOINT SEAL BOOT . . . . . . . . . . . 7

FRONT DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS. . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
DRIVESHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY AND ASSEMBLY
DRIVESHAFT RECONDITION . . . . . . . . . . . . . . . . 7
OUTER C/V JOINT SEAL BOOT . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SPECIAL TOOLS
DRIVESHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DESCRIPTION AND OPERATION The system incorporates two driveshaft assemblies

(left and right) that consist of an inner and outer
FRONT DRIVESHAFTS constant velocity (CV) joint and a solid interconnect-
Vehicles equipped with either an automatic or ing shaft (Fig. 1). The right driveshaft is longer than
manual transmission use an unequal–length drive- the left due to transaxle packaging and powertrain
shaft system. design.

Fig. 1 Unequal Length Driveshaft System

1 – STUB AXLE 8 – OUTER C/V JOINT
2 – OUTER C/V JOINT 9 – RIGHT DRIVESHAFT
3 – OUTER C/V JOINT BOOT 10 – INNER TRIPOD JOINT BOOT
4 – TUNED RUBBER DAMPER WEIGHT 11 – INNER TRIPOD JOINT
5 – INTERCONNECTING SHAFT 12 – INNER TRIPOD JOINT
6 – OUTER C/V JOINT BOOT 13 – INNER TRIPOD JOINT BOOT
7 – STUB AXLE 14 – INTERCONNECTING SHAFT LEFT DRIVESHAFT
3-2 DIFFERENTIAL AND DRIVELINE
DESCRIPTION AND OPERATION (Continued)
Driveshafts used on both the right and left sides of
the vehicle use a tuned rubber damper weight
mounted to the interconnecting shaft (Fig. 1). The
damper weight applications vary by which side of the
vehicle the driveshaft is located on and the transmis-
sion application of the vehicle. When replacing a
driveshaft, be sure the replacement driveshaft has
the same damper weight as the original.
Both driveshaft assemblies use the same type of
inner and outer joints. The inner joint of both drive-
shaft assemblies is a tripod joint, and the outer joint
of both driveshaft assemblies is a Rzeppa joint. Both
tripod joints and Rzeppa joints are true constant
velocity (C/V) joint assemblies. The inner tripod joint
allows for the changes in driveshaft length through
the jounce and rebound travel of the front suspen-
sion.
On vehicles equipped with ABS brakes, the outer
C/V joint is equipped with a tone wheel used to
determine vehicle speed for ABS brake operation.
The inner tripod joint of both driveshafts is splined
into the transaxle side gears. The inner tripod joints
are retained in the side gears of the transaxle using
a snap ring located in the stub shaft of the tripod
joint. The outer C/V joint has a stub shaft that is
splined into the wheel hub and retained by a single
piece steel hub nut (Fig. 2). The hub nut is a locking
style; the nut lock, anti-rattle washer, and cotter pin
are not necessary.
Fig. 2 Driveshaft Retaining Nut
1 – DRIVESHAFT
2 – HUB
3 – HUB NUT
PL
NOTE: This vehicle does not use a rubber–lip bear-
ing seal as on previous front–wheel–drive cars to
prevent contamination of the front wheel bearing.
On these vehicles, the face of the outer C/V joint
fits deeply into the steering knuckle, using a close
outer C/V joint–to–steering knuckle fit. This design
deters direct water splash on bearing seal while
allowing any water that gets in, to run out the bot-
tom of the steering knuckle bearing bore. It is
important to thoroughly clean the outer C/V joint
and the wheel bearing area in the steering knuckle
before it is assembled after servicing.
DIAGNOSIS AND TESTING
DRIVESHAFT DIAGNOSIS
VEHICLE INSPECTION
(1) Check for grease in the vicinity of the inboard
tripod joint and outboard C/V joint; this is a sign of
inner or outer joint seal boot or seal boot clamp dam-
age.
(2) A light film of grease may appear on the right
inner tripod joint seal boot; this is considered normal
and should not require replacement of the seal boot.
The right inner tripod joint seal boot is made of sili-
cone rubber; which will allow the weeping (sweating)
of the joint lubricant to pass through it while in oper-
ation.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could
be caused by one of the following conditions.
(1) Damaged outer C/V or inner tripod joint seal
boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease, resulting in
inadequate lubrication of the joint.
(2) Noise may also be caused by another compo-
nent of the vehicle coming in contact with the drive-
shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following
conditions:
(1) A torn seal boot on the inner or outer joint of
the driveshaft assembly.
(2) A loose or missing clamp on the inner or outer
joint of the driveshaft assembly.
(3) A damaged or worn driveshaft C/V joint.
PL DIFFERENTIAL AND DRIVELINE 3-3
DIAGNOSIS AND TESTING (Continued)
SHUDDER OR VIBRATION DURING ACCELERATION
(1) A worn or damaged driveshaft inner tripod
joint.
(2) A sticking tripod joint spider assembly (inner
tripod joint only).
(3) Improper wheel alignment. See Wheel Align-
ment in this group for alignment checking and set-
ting procedures and specifications.

VIBRATION AT HIGHWAY SPEEDS

(1) Foreign material (mud, etc.) packed on the
backside of the wheel(s).
(2) Out of balance front tires or wheels. See Group
22, Wheels And Tires for the required balancing pro-
cedure. Fig. 3 Wheel and Tire Removal
1 – WHEEL/TIRE ASSY.
(3) Improper tire and/or wheel runout. See Group
2 – LUG NUT (5)
22, Wheels And Tires for the required runout check-
3 – HUB
ing procedure.

(5) Remove the driveshaft to hub and bearing

REMOVAL AND INSTALLATION retaining nut (Fig. 4).

DRIVESHAFTS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the driveshaft
to prevent damage.

REMOVAL
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels Fig. 4 Driveshaft Retaining Nut Removal
with a driveshaft removed, install a PROPER–SIZED 1 – DRIVESHAFT
BOLT AND NUT through front hub. Tighten bolt and 2 – HUB
3 – HUB NUT
nut to 203 N·m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
(6) If equipped with ABS, disconnect the front
(1) Disconnect battery negative cable. wheel speed sensor and secure harness out of the
(2) Place transaxle in gated park. way.
(3) Raise vehicle on hoist.
(4) Remove wheel and tire assembly (Fig. 3).
3-4 DIFFERENTIAL AND DRIVELINE
REMOVAL AND INSTALLATION (Continued)
(7) Remove nut and bolt (Fig. 5) retaining ball
joint stud into steering knuckle.
PL
NOTE: Care must be taken not to separate the
inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint, driveshaft
must be supported.

(9) Remove driveshaft from steering knuckle by

pulling outward on knuckle while pressing in on
driveshaft. Support outer end of driveshaft assembly.
If difficulty in separating driveshaft from steering
knuckle is encountered, perform the following proce-
dure:
(a) Install Puller, Special Tool 6790 on hub and
bearing assembly (Fig. 7), using wheel lug nuts to
secure it in place.
(b) Install a wheel lug nut on wheel stud to pro-
tect the threads on the stud. Install a flat blade
pry tool to keep hub from turning. Using Puller,
force the driveshaft outer stub axle from the hub
Fig. 5 Steering Knuckle at Lower Control Arm Ball and bearing assembly (Fig. 8).
Joint (c) Pull steering knuckle assembly out and away
1 – NUT from outer C/V joint of the driveshaft assembly as
2 – BOLT shown in (Fig. 5).
3 – BALL JOINT

NOTE: Use caution when separating ball joint stud

from steering knuckle, so ball joint seal does not
get damaged.

(8) Separate ball joint stud from steering knuckle

by prying down on lower control arm (Fig. 6).

Fig. 7 Puller Installed On Hub/Bearing Assembly

1 – TOOL 6790

(10) Support outer end of the driveshaft assembly.

NOTE: Removal of the inner tripod joints is made

easier if you apply outward pressure on the joint as
you strike the punch with a hammer.
Fig. 6 Separating Lower Control Arm from Steering
Knuckle
1 – STEERING KNUCKLE
2 – PRY BAR
3 – LOWER CONTROL ARM
4 – BALL JOINT STUD
PL DIFFERENTIAL AND DRIVELINE 3-5
REMOVAL AND INSTALLATION (Continued)

Fig. 8 Removing Stub Axle From Hub/Bearing Fig. 10 Disengaging Left Inner Tripod Joint from
1 – TOOL 6790 Transaxle
1 – FRONT SUSPENSION CROSSMEMBER
2 – DRIFT
(11) Remove the inner tripod joints from the side 3 – TRANSAXLE
gears of the transaxle using a punch to dislodge the 4 – DRIVESHAFT INNER TRIPOD JOINT
inner tripod joint retaining ring from the transaxle 5 – NOTCH
side gear. If removing the right side inner tripod
joint, position the punch against the inner tripod (12) Hold inner tripod joint and interconnecting
joint (Fig. 9). Strike the punch sharply with a ham- shaft of driveshaft assembly (Fig. 11). Remove inner
mer to dislodge the right inner joint from the side tripod joint from transaxle by pulling it straight out
gear. If removing the left side inner tripod joint, posi- of transaxle side gear and transaxle oil seal. When
tion the punch in the groove of the inner tripod joint removing tripod joint, do not let spline or snap
(Fig. 10). Strike the punch sharply with a hammer to ring drag across sealing lip of the transaxle to
dislodge the left inner tripod joint from the side gear. tripod joint oil seal. When tripod joint is
removed from transaxle, some fluid will leak
out.

Fig. 9 Disengaging Right Inner Tripod Joint from

Transaxle
1 – TRANSAXLE Fig. 11 Tripod Joint Removal from Transaxle
2 – RIGHT INNER TRIPOD JOINT 1 – INNER TRIPOD JOINT
3 – PUNCH 2 – TRANSAXLE
3 – SPLINE
4 – OIL SEAL
5 – SNAP RING
6 – INTERCONNECTING SHAFT
3-6 DIFFERENTIAL AND DRIVELINE PL
REMOVAL AND INSTALLATION (Continued)
CAUTION: The driveshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a driveshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 203 N·m (150 ft. lbs.). This will ensure that
the hub bearing cannot loosen.

INSTALLATION
(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding driveshaft assembly by tripod joint and
interconnecting shaft, install tripod joint into tran-
saxle side gear as far as possible by hand.
Fig. 13 Outer C/V Joint Inspection
(3) Carefully align tripod joint with transaxle side
1 – OUTER C/V JOINT
gears. Then grasp driveshaft interconnecting shaft 2 – THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
and push tripod joint into transaxle side gear until DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
fully seated. Test that snap ring is fully engaged STEERING KNUCKLE.
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is (6) Slide driveshaft back into front hub. Install
fully engaged with side gear, tripod joint will steering knuckle onto the ball joint stud (Fig. 14).
not be removable by hand.
(4) Clean all debris and moisture out of steering NOTE: At this point, the outer joint will not seat
knuckle (Fig. 12). completely into the front hub. The outer joint will be
pulled into hub and seated when the hub nut is
installed and torqued.

(7) Install a NEW steering knuckle to ball joint

stud bolt and nut (Fig. 14). Tighten the nut and bolt
to 95 N·m (70 ft. lbs.).

Fig. 12 Steering Knuckle to C/V Joint Sealing Area

1 – STEERING KNUCKLE
2 – WHEEL BEARING
3 – FRONT HUB
4 – THIS AREA OF THE STEERING KNUCKLE IS TO BE FREE
OF ALL DEBRIS AND MOISTURE BEFORE INSTALLING
DRIVE SHAFT IN STEERING KNUCKLE
Fig. 14 Driveshaft Installation Into Hub And Steering
Knuckle
(5) Ensure that front of outer C/V joint, which fits 1 – NUT
into steering knuckle (Fig. 13), is free of debris and 2 – BOLT
moisture before assembling into steering knuckle. 3 – BALL JOINT
PL
REMOVAL AND INSTALLATION (Continued)
(8) Clean all foreign matter from threads of drive-
shaft outer stub axle. Install hub nut onto the
threads of the stub axle and tighten nut to 244 N·m
(180 ft. lbs.) (Fig. 15).
DIFFERENTIAL AND DRIVELINE 3-7
(10) Check for correct fluid level in transaxle
assembly. Refer to Group 21 Transaxle, for the cor-
rect fluid level checking procedure for the type of
transaxle being checked.
(11) Lower vehicle.
(12) Connect battery negative cable.

DISASSEMBLY AND ASSEMBLY

DRIVESHAFT RECONDITION
NOTE: The only service that is to be performed on
the driveshaft assemblies is the replacement of the
driveshaft seal boots.

If any failure of internal driveshaft components is

diagnosed during a vehicle road test or disassembly
of the driveshaft, the driveshaft will need to be
replaced as an assembly.

Fig. 15 Driveshaft Retaining Nut Installation NOTE: Lubricant requirements and quantities are
1 – DRIVESHAFT different for inner joints than for outer joints. Use
2 – HUB only the recommended lubricants in the required
3 – HUB NUT quantities when servicing driveshaft assemblies.

(9) Install front wheel and tire assembly. Install See (Fig. 17) for the exploded view of the front
front wheel lug nuts (Fig. 16) and tighten to 128 N·m driveshaft components.
(95 ft. lbs.).
INNER TRIPOD JOINT SEAL BOOT
REMOVAL
To remove sealing boot from driveshaft for replace-
ment, the driveshaft assembly must be removed from
the vehicle. See Driveshaft Removal and Installation
in this section for the required driveshaft removal
and replacement procedure.
The inner tripod joints use no internal retention in
the tripod housing to keep the spider assembly in the
housing. Therefore, do not pull on the interconnect-
ing shaft to disengage tripod housing from transmis-
sion stub shaft. Removal in this manner will cause
damage to the inboard joint sealing boots.
(1) Remove the driveshaft requiring boot replace-
Fig. 16 Wheel and Tire Installation
ment from the vehicle. See Driveshaft Removal and
1 – WHEEL/TIRE ASSY.
2 – LUG NUT (5)
Installation in this section for the required driveshaft
3 – HUB removal procedure.
(2) Remove large boot clamp that retains inner tri-
pod joint sealing boot to tripod joint housing (Fig. 18)
and discard. Then remove small clamp that retains
inner tripod joint sealing boot to interconnecting
shaft and discard. Remove the sealing boot from the
tripod housing and slide it down the interconnecting
shaft.
3-8 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 17 Driveshaft Assembly Components (Exploded View)

1 – HOUSING ASM, RETAINER & 11 – CLAMP, SEAL RETAINING
2 – RING, SPACER 12 – SHAFT, AXLE (RH SHOWN, LH SIMILAR)
3 – SPIDER, TRIPOTD JOINT 13 – SEAL, DRIVE AXLE OUTBOARD
4 – RING, RETAINING 14 – CLAMP, SEAL RETAINING
5 – RETAINER, BALL & ROLLER 15 – RING, RACE RETAINING
6 – BALL, TRIPOD JOINT 16 – BALL, CHROME ALLOY
7 – ROLLER, NEEDLE 17 – RACE, C/V JOINT INNER
8 – CLAMP, SEAL RETAINING 18 – CAGE, C/V JOINT
9 – BUSHING, TRILOBAL TRIPOD 19 – RACE, C/V JOINT OUTER
10 – SEAL, DRIVE AXLE INBOARD
PL DIFFERENTIAL AND DRIVELINE 3-9
DISASSEMBLY AND ASSEMBLY (Continued)
can be removed by tapping spider assembly with a
brass drift (Fig. 21). Do not hit the outer tripod
bearings in an attempt to remove spider assem-
bly from interconnecting shaft.

Fig. 18 Inner Tripod Joint Sealing Boot Clamps

1 – SMALL CLAMP
2 – LARGE CLAMP
3 – INNER TRIPOD JOINT
4 – SEALING BOOT Fig. 20 Spider Assembly Retaining Snap Ring
5 – INTERCONNECTING SHAFT 1 – INTERCONNECTING SHAFT
2 – SPIDER ASSEMBLY
3 – RETAINING SNAP RING
CAUTION: When removing the spider joint from the
tripod joint housing, hold the rollers in place on the
spider trunions to prevent the rollers and needle
bearings from falling away.

(3) Slide the interconnecting shaft and spider

assembly out of the tripod joint housing (Fig. 19).

Fig. 21 Spider Assembly Removal from

Fig. 19 Spider Assembly Joint Removal from
Housing
1 – TRIPOD JOINT HOUSING
2 – SPIDER ASSEMBLY
3 – SEALING BOOT
(4) Remove snap ring that retains spider assembly
to interconnecting shaft (Fig. 20). Remove the spider
assembly from interconnecting shaft. If spider assem-
bly will not come off interconnecting shaft by hand, it
Interconnecting Shaft
1 – SPIDER ASSEMBLY
2 – DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN
REMOVING SPIDER ASSEMBLY
3 – BRASS DRIFT
4 – INTERCONNECTING SHAFT
(5) Slide sealing boot off interconnecting shaft.
(6) Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for
any signs of excessive wear. If any parts show
signs of excessive wear, the driveshaft assembly
will require replacement. Component parts of
these driveshaft assemblies are not serviceable.
3 - 10 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
INSTALLATION
NOTE: The inner tripod joint sealing boots are
made from two different types of material. High–
temperature applications use silicone rubber
whereas standard temperature applications use
Hytrel plastic. The silicone sealing boots are soft
and pliable. The Hytrel sealing boots are stiff and
rigid. The replacement sealing boot MUST BE the
same type of material as the sealing boot that was
removed.

(1) Slide inner tripod joint seal boot retaining

clamp, onto interconnecting shaft. Then slide the
replacement inner tripod joint sealing boot onto
interconnecting shaft. Inner tripod joint seal boot
MUST be positioned on interconnecting shaft, Fig. 23 Spider Assembly Installation on
so the raised bead on the inside of the seal boot Interconnecting Shaft
is in groove on interconnecting shaft (Fig. 22). 1 – SPIDER ASSEMBLY
2 – INTERCONNECTING SHAFT
3 – CHAMFER

Fig. 22 Sealing Boot Installation on Interconnecting

Shaft
1 – SEALING BOOT
2 – RAISED BEAD IN THIS AREA OF SEALING BOOT
3 – GROOVE
4 – INTERCONNECTING SHAFT
(2) Install spider assembly onto interconnecting
shaft with chamfer on spider assembly toward inter-
connecting shaft (Fig. 23). Spider assembly must be
installed on interconnecting shaft far enough to fully
install spider retaining snap ring. If spider assembly
will not fully install on interconnecting shaft by
hand, it can be installed by tapping the spider body
with a brass drift (Fig. 24). Do not hit the outer
tripod bearings in an attempt to install spider
assembly on interconnecting shaft.
(3) Install the spider assembly to interconnecting
shaft retaining snap ring into groove on end of inter-
connecting shaft (Fig. 25). Be sure the snap ring is
fully seated into groove on interconnecting shaft.
Fig. 24 Installing Spider Assembly On
Interconnecting Shaft
1 – DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER
ASSEMBLY
2 – SPIDER ASSEMBLY
3 – INTERCONNECTING SHAFT
4 – BRASS DRIFT
(4) Distribute 1/2 the amount of grease provided in
the seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into tripod housing. Put
the remaining amount into the sealing boot.
(5) Align tripod housing with spider assembly and
then slide tripod housing over spider assembly and
interconnecting shaft (Fig. 26).
(6) Install inner tripod joint seal boot to intercon-
necting shaft clamp evenly on sealing boot.
PL DIFFERENTIAL AND DRIVELINE 3 - 11
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 25 Spider Assembly Retaining Snap Ring

Fig. 27 Crimping Tool Installed on Sealing Boot
Installed
Clamp
1 – INTERCONNECTING SHAFT
1 – SPECIAL TOOL C-4975A
2 – SPIDER ASSEMBLY
2 – INTERCONNECTING SHAFT
3 – RETAINING SNAP RING
3 – CLAMP
4 – SEALING BOOT

Fig. 26 Installing Tripod Housing on Spider

Assembly
1 – TRIPOD JOINT HOUSING
2 – SPIDER ASSEMBLY
3 – SEALING BOOT
(7) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow-
ing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 27). Tighten nut on crimping
tool C-4975-A until jaws on tool are closed completely
together, face to face (Fig. 28).
CAUTION: Seal must not be dimpled, stretched, or
out–of–shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
Fig. 28 Sealing Boot Retaining Clamp Installed
1 – CLAMP
2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
3 – INTERCONNECTING SHAFT
4 – SEALING BOOT
(8) Position sealing boot into the tripod housing
retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
CAUTION: The following positioning procedure
determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing
boot to inner tripod joint housing. If this procedure
is not done prior to clamping sealing boot to tripod
joint housing, boot durability can be adversely
affected.
3 - 12 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
CAUTION: When venting the inner tripod joint
assembly, use care so inner tripod sealing boot
does not get punctured or, in any other way, dam-
aged. If sealing boot is punctured or damaged while
being vented, the sealing boot can not be used.

(9) Insert a trim stick between the tripod joint and

the sealing boot to vent inner tripod joint assembly
(Fig. 29). When inserting trim stick between tri-
pod housing and sealing boot, ensure trim stick
is held flat and firmly against the tripod hous-
ing. If this is not done, damage to the sealing
boot can occur. If inner tripod joint has a Hytrel
(hard plastic) sealing boot, be sure trim stick is
inserted between soft rubber insert and tripod hous-
ing, and not the hard plastic sealing boot and soft
rubber insert. Fig. 30 Sealing Boot End to End Length with Hytrel
Boot
1 – 107 MILLIMETERS
2 – HYTREL SEALING BOOT
3 – SEALING BOOT CLAMP
4 – INNER TRIPOD JOINT

Fig. 29 Trim Stick Inserted for Venting Tripod Joint

1 – INNER TRIPOD JOINT SEALING BOOT
2 – SEALING BOOT CLAMP
3 – INNER TRIPOD JOINT HOUSING
4 – TRIM STICK
Fig. 31 Sealing Boot End to End Length with
(10) With trim stick inserted between sealing boot Silicone Boot
1 – 115 MILLIMETERS
and tripod joint housing, position inner tripod joint
2 – SILICONE SEALING BOOT
on driveshaft until correct sealing boot edge to edge
3 – CLAMP
length is obtained for type of sealing boot material 4 – INNER TRIPOD JOINT
being used (Fig. 30) (Fig. 31). Then remove the trim
stick.
(11) Clamp tripod joint sealing boot to tripod joint (12) If seal boot uses low profile latching type boot
using required procedure for type of boot clamp clamp, clamp sealing boot onto tripod housing using
application. If seal boot uses crimp type boot clamp, clamp locking tool, Snap-Ont YA3050 (or an equiva-
clamp sealing boot onto tripod housing using crimper, lent). Place prongs of clamp locking tool in the holes
Special Tool C-4975-A. Place crimping tool C-4975-A of the clamp (Fig. 34). Squeeze tool together until top
over bridge of clamp (Fig. 32). Tighten nut on crimp- band of clamp is latched behind the two tabs on
ing tool C-4975-A until jaws on tool are closed com- lower band of clamp (Fig. 35).
pletely together, face–to–face (Fig. 33).
PL DIFFERENTIAL AND DRIVELINE 3 - 13
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 32 Crimping Tool Installed on Sealing Boot Fig. 34 Clamping Tool Installed on Sealing Boot
Clamp Clamp
1 – CLAMP 1 – CLAMP
2 – TRIPOD JOINT HOUSING 2 – SPECIAL TOOL YA3050
3 – SPECIAL TOOL C-4975A 3 – SEALING BOOT
4 – SEALING BOOT

Fig. 35 Sealing Boot Clamp Correctly Installed

Fig. 33 Sealing Boot Retaining Clamp Installed 1 – INNER TRIPOD JOINT HOUSING
1 –
CLAMP 2 – TOP BANK OF CLAMP MUST BE RETAINED BY TABS AS
2 –
TRIPOD HOUSING SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP
3 –
SPECIAL TOOL C-4975A 3 – SEALING BOOT
4 –
JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 – SEALING BOOT OUTER C/V JOINT SEAL BOOT

(13) Install the driveshaft requiring boot replace- REMOVAL

ment back on the vehicle. See Driveshaft Removal
and Installation in this section for the required drive-
shaft installation procedure.
To remove outer C/V joint sealing boot from a drive-
shaft for replacement, the driveshaft assembly must
be removed from the vehicle. See Driveshaft Removal
and Installation in this section for the required drive-
shaft removal and replacement procedure.
(1) Remove driveshaft assembly requiring boot
replacement from vehicle. See Driveshaft Removal
and Installation in this section for the required drive-
shaft removal procedure.
3 - 14 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove large boot clamp retaining C/V joint
sealing boot to C/V joint housing (Fig. 36) and dis-
card. Remove small clamp that retains outer C/V
joint sealing boot to interconnecting shaft and dis-
card. Remove sealing boot from outer C/V joint hous-
ing and slide it down interconnecting shaft.

Fig. 37 Outer C/V Joint Removal from

Interconnecting Shaft
1 – SOFT HAMMER (TAP HOUSING)
2 – WEAR SLEEVE
3 – CIRCLIP (OUTER END OF SHAFT)

Fig. 36 Outer C/V Joint Seal Boot Clamps

1 – SMALL CLAMP
2 – SEALING BOOT
3 – OUTER C/V JOINT HOUSING
4 – LARGE CLAMP
5 – INTERCONNECTING SHAFT

(3) Wipe away grease to expose outer C/V joint and

interconnecting shaft.
(4) Remove outer C/V joint from interconnecting
shaft using the following procedure: Support inter-
connecting shaft in a vise equipped with protec-
tive caps on jaws of vise to prevent damage to
interconnecting shaft. Then, using a soft–faced
hammer, sharply hit the end of the C/V joint hous-
ing to dislodge housing from internal circlip on inter-
connecting shaft (Fig. 37). Then slide outer C/V joint
off end of interconnecting shaft, joint may have to be
tapped off shaft using a soft–faced hammer.
(5) Remove large circlip (Fig. 38) from the inter-
connecting shaft before attempting to remove outer
C/V joint sealing boot.
(6) Slide failed sealing boot off interconnecting
shaft.
(7) Thoroughly clean and inspect outer C/V joint
assembly and interconnecting joint for any signs of
excessive wear. If any parts show signs of exces-
sive wear, the driveshaft assembly will require
replacement. Component parts of these drive-
shaft assemblies are not serviceable.
INSTALLATION
(1) Slide new sealing boot to interconnecting shaft
retaining clamp onto interconnecting shaft. Slide the
Fig. 38 Circlip Removal from Interconnecting Shaft
1 – SNAP RING PLIERS
2 – INTERCONNECTING SHAFT
3 – CIRCLIP
outer C/V joint assembly sealing boot onto the inter-
connecting shaft (Fig. 39). Seal boot MUST be
positioned on interconnecting shaft so the
raised bead on the inside of the seal boot is in
groove on interconnecting shaft.
(2) Align splines on interconnecting shaft with
splines on cross of outer C/V joint assembly and start
outer C/V joint onto interconnecting shaft.
(3) Install outer C/V joint assembly onto intercon-
necting shaft by using a soft–faced hammer and
tapping end of stub axle (with nut installed) until
outer C/V joint is fully seated on interconnecting
shaft (Fig. 40).
PL DIFFERENTIAL AND DRIVELINE 3 - 15
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 39 Sealing Boot Installation on Interconnecting

Shaft Fig. 41 Outer C/V Joint Correctly Installed on
1 – SEALING BOOT
Interconnecting Shaft
2 – RAISED BEAD IN THIS AREA OF SEALING BOOT 1 – INTERCONNECTING SHAFT
3 – GROOVE 2 – CROSS
4 – INTERCONNECTING SHAFT 3 – OUTER C/V JOINT ASSEMBLY

(6) Install outer C/V joint sealing boot to intercon-

necting shaft clamp evenly on sealing boot.
(7) Clamp sealing boot onto interconnecting shaft
using crimper, Special Tool C-4975-A and the follow-
ing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 42). Tighten nut on crimping
tool C- 4975-A until jaws on tool are closed com-
pletely together, face to face (Fig. 43).

Fig. 40 Outer C/V Joint Installation on

Interconnecting Shaft
1 – SOFT FACED HAMMER
2 – STUB AXLE
3 – OUTER C/V JOINT
4 – NUT

(4) Outer C/V joint assembly must be installed on

interconnecting shaft until cross of outer C/V joint
assembly is seated against circlip on interconnecting Fig. 42 Crimping Tool Installed on Sealing Boot
shaft (Fig. 41). Clamp
(5) Distribute 1/2 the amount of grease provided in 1 – SPECIAL TOOL C-4975A
2 – INTERCONNECTING SHAFT
seal boot service package (DO NOT USE ANY
3 – CLAMP
OTHER TYPE OF GREASE) into outer C/V joint
4 – SEALING BOOT
assembly housing. Put the remaining amount into
the sealing boot.
3 - 16 DIFFERENTIAL AND DRIVELINE PL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 43 Sealing Boot Retaining Clamp Installed Fig. 44 Crimping Tool Installed on Sealing Boot
1 – CLAMP Clamp
2 – JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED 1 – CLAMP
COMPLETELY TOGETHER HERE
2 – TRIPOD JOINT HOUSING
3 – INTERCONNECTING SHAFT
3 – SPECIAL TOOL C-4975A
4 – SEALING BOOT
4 – SEALING BOOT

CAUTION: Seal must not be dimpled, stretched, or

out–of–shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.

(8) Position outer C/V joint sealing boot into its

retaining groove on outer C/V joint housing. Install
sealing boot to outer C/V joint retaining clamp evenly
on sealing boot.
(9) Clamp sealing boot onto outer C/V joint hous-
ing using Crimper, Special Tool C-4975-A and the fol-
lowing procedure. Place crimping tool C-4975-A over
bridge of clamp (Fig. 44). Tighten nut on crimping
tool C-4975-A until jaws on tool are closed completely
together, face to face (Fig. 45).
(10) Install the driveshaft requiring boot replace-
ment back on the vehicle. See Driveshaft Removal
Fig. 45 Sealing Boot Retaining Clamp Installed
and Installation in this section for the required drive-
1 –
CLAMP
shaft installation procedure. 2 –
TRIPOD HOUSING
3 –
SPECIAL TOOL C-4975A
4 –
JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
COMPLETELY TOGETHER HERE
5 – SEALING BOOT
PL DIFFERENTIAL AND DRIVELINE 3 - 17

SPECIFICATIONS SPECIAL TOOLS

TORQUE DRIVESHAFT
DESCRIPTION TORQUE
Driveshaft-to-Hub/Bearing
Nut . . . . . . . . . . . . . . . . . . . 244 N·m (180 ft. lbs.)
Knuckle-to-Ball Joint
Bolt/Nut . . . . . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)
Wheel/Tire-to-Hub/Bearing
Lug Nuts . . . . . . . . . . . . . . . 128 N·m (95 ft. lbs.)

Boot Clamp Installer C-4975A

Puller 6790